The internal pressure of aerosol dispensers at 50 °C shall exceed neither two-thirds of the test pressure
nor 1.32 MPa (13.2 bar). They shall be so filled that at 50 °C the liquid phase does not exceed 95% of
their capacity. Small receptacles containing gas (gas cartridges) shall meet the test pressure and filling
requirements of packing instruction P200 of 184.108.40.206. In addition, the product of test pressure and water
capacity shall not exceed 30 bar.litres for liquefied gases or 54 bar.litres for compressed gases and the
test pressure shall not exceed 250 bar for liquefied gases or 450 bar for compressed gases.
Hydraulic pressure test
The internal pressure to be applied (test pressure) shall be 1.5 times the internal pressure at 50 °C,
with a minimum pressure of 1 MPa (10 bar).
The hydraulic pressure tests shall be carried out on at least five empty receptacles of each model:
(a) until the prescribed test pressure is reached, by which time no leakage or visible permanent
deformation shall have occurred; and
(b) until leakage or bursting occurs; the dished end, if any, shall yield first and the receptacle
shall not leak or burst until a pressure 1.2 times the test pressure has been reached or passed.
Tightness (leakproofness) test
Each filled aerosol dispenser or gas cartridge or fuel cell cartridge shall be subjected to a test in a hot
water bath in accordance with 220.127.116.11.1 or an approved water bath alternative in accordance with
Hot water bath test
The temperature of the water bath and the duration of the test shall be such that the internal pressure
reaches that which would be reached at 55 °C (50 °C if the liquid phase does not exceed 95% of the
capacity of the aerosol dispenser, gas cartridge or the fuel cell cartridge at 50 °C). If the contents are
sensitive to heat or if the aerosol dispensers, gas cartridges or the fuel cell cartridges are made of
plastics material which softens at this test temperature, the temperature of the bath shall be set at
between 20 °C and 30 °C but, in addition, one aerosol dispenser, gas cartridge or the fuel cell cartridge
in 2 000 shall be tested at the higher temperature.
No leakage or permanent deformation of an aerosol dispenser, gas cartridge or the fuel cell cartridge
may occur, except that a plastic aerosol dispenser, gas cartridge or the fuel cell cartridge may be
deformed through softening provided that it does not leak.
With the approval of the competent authority alternative methods that provide an equivalent level of
safety may be used provided that the requirements of 18.104.22.168.2.1 and, as appropriate, 22.214.171.124.2.2 or
126.96.36.199.2.3 are met.
Aerosol dispenser, gas cartridge or the fuel cell cartridge fillers and component manufacturers
have a quality system. The quality system shall implement procedures to ensure that all aerosol
dispensers, gas cartridges or the fuel cell cartridges that leak or that are deformed are rejected
and not offered for transport.
The quality system shall include:
(a) A description of the organizational structure and responsibilities;
(b) The relevant inspection and test, quality control, quality assurance, and process operation
instructions that will be used;
(c) Quality records, such as inspection reports, test data, calibration data and certificates;
(d) Management reviews to ensure the effective operation of the quality system;
(e) A process for control of documents and their revision;
(f) A means for control of non-conforming aerosol dispensers, gas cartridges or the fuel cell
(g) Training programmes and qualification procedures for relevant personnel; and
(h) Procedures to ensure that there is no damage to the final product.
An initial audit and periodic audits shall be conducted to the satisfaction of the competent
These audits shall ensure the approved system is and remains adequate and efficient. Any proposed
ved system shall be notified to the competent authority in advance.
Pressure and leak testing of aerosol dispensers before filling
Each empty aerosol dispenser shall be subjected to a pressure equal to or in excess of the maximum
expected in the filled aerosol dispensers at 55 °C (50 °C if the liquid phase does not exceed 95% of
the capacity of the receptacle at 50 °C). This shall be at least two-thirds of the design pressure of the
aerosol dispenser. If any aerosol dispenser shows evidence of leakage at a rate equal to or greater than
3.3 × 10-2 mbar.l.s-1 at the test pressure, distortion or other defect, it shall be rejected.
Testing of the aerosol dispensers after filling
Prior to filling the filler shall ensure that the crimping equipment is set appropriately and the specified
propellant is used.
Each filled aerosol dispenser shall be weighed and leak tested. The leak detection equipment shall be
sufficiently sensitive to detect at least a leak rate of 2.0 × 10-3 mbar.l.s-1 at 20 °C.
Any filled aerosol dispenser that shows evidence of leakage, deformation or excessive mass shall be
Gas cartridges and fuel cell cartridges
Pressure testing of gas cartridges and fuel cell cartridges
Each gas cartridge or fuel cell cartridge shall be subjected to a test pressure equal to or in excess of the
maximum expected in the filled receptacle at 55 °C (50 °C if the liquid phase does not exceed 95% of
the capacity of the receptacle at 50 °C). This test pressure shall be that specified for the gas cartridge
or fuel cell cartridge and shall not be less than two thirds the design pressure of the gas cartridge or
fuel cell cartridge. If any gas cartridge or fuel cell cartridge shows evidence of leakage at a rate equal
to or greater than 3.3 × 10-2 mbar.l.s-1 at the test pressure or distortion or any other defect, it shall be